A crosslinked, flame-retardant resin composition and the insulated wire having layer using the above composition

Abstract: The composition of the present invention is a kind of crosslinked, flame -retardant resin composition, which comprises a base polymer of EVA-VC, chlorinated polyethylene, thermal stabilizers, antioxidants, flame-retardant fillers, lubricants and monomers with multifunctional group. The composition essentially comprises 100 weight parts of EVA-VC, 10 to 70 weight parts of chlorinated polyethylene, 40 to 120 weight parts of flame-retardant fillers, and 5 to 20 weight parts of monomer with multifunctional group. In addition, the composition is crosslinked by electron beam to be used as the material for sheath layer of electric wire or cable durable to high voltages.

Description: The present invention, in general, relates to a crosslinked, flame-retarded resin composition and the insulated wire having a sheath layer, and particularly to a crosslinked, flame-retardant resin composition capable of protecting a flammable inner material from a direct fire and an insulated wire having a sheath layer using the above composition. It is known to those skilled to the art that an insulated wire used in high voltage-operating electric equipment such as television sets, microwave ovens, and duplicators etc. has such a structure that an electric wire is coated with an insulating layer which is encapsulated with a protecting sheath layer. As an insulating layer for the insulated wire, there has been used a polymer of polyethlylene or polypropylene. The polymers have such an excellent insulation resistance property that they are endurable to high voltages up to several tens of KVs. Such polymers, however, have a disadvantage of being combustible in themselves. To overcome the combustible property of polyethylene or polypropylene, in general, additives such as flame-retardant fillers are added. The addition of such additives, however, causes the insulation resistance property of the polymers to deteriorate in spite of giving an improvement of flame-retardancy to them. So, the wire coated with the polymers having such additives is not suitable for a high voltage-operating equipment. In an effort to make up for the deficient property of flammability of the polymers, a material for a sheath layer which protects the flammable insulating layer is made to have an excellent property of flame-retardancy. Polyvinylchloride, crosslinked polyvinylchloride or crosslinked flame-retardant polyethylene has been chiefly used for a conventional sheath layer. When they are made to have a property of high flame-retardancy, mechanical properties and flexibility thereof are deteriorated so largely that the wire sheathed with them is unsatisfactory to be applied to electrical equipment. In fact, the sheath layer of insulated wire is not necessarily to have high insulation resistance. It is preferable to minimize deterioration of flexibility as much as possible when the material for sheath layer is made to have an excellent property of flame-retardancy. The above mentioned conventional materials for sheath layer have an excellent property of flame-retardancy and yet, do not show good flexibility. Thus, the above mentioned conventional materials are not desirable for sheath materials of insulated wire in the viewpoint of flame-retardancy and flexibility. EP-A-73613 discloses a resin composition containing : 5 to 80% by weight of graft copolymer prepared by grafting polyvinyl chloride (PVC) to an ethylene-vinyl acetate copolymer (EVA) ; 95 to 20% by weight of chlorinated polyethylene; flame-retardant fillers comprising 2,2-di(4-bromothoxy-3,5-dibromophényl)propane ; and a polyfunctional monomer. The grafting of PVC to EVA leads to provide flame-retardant properties improved by the addition of flame-retardant fillers. However, the addition of these flame-retardant fillers 2,2-di(4-bromothoxy-3,5-dibromophenyl)propane) does not improve greatly the flame retardant properties of the resin. Morover, EP-A-736l3 discloses that the resin composition of the invention has good transparency, but notices that this property is hardly compatible with good flexibily. In order to improve the flame-retardant property of EVA-VC polymer, flame retardant fillers such as antimony trioxide are added to EVA-VC. EP-A-73613 suggests the addition of antimony trioxide to improve flame retardancy, but also rejects this solution antimony trioxide having the drawback of deteriorating transparency. JP-A-49015741 discloses fire-resistant compositions prepared from graft polymer 100, chlorinated polyethylene 15,75 and Sb 2 O 3 1,5-30 parts. Some of the compositions have also low temperature flexibility when the graft polymer is prepared from vinyl chloride-ethylene-vinyl acetate with vinyl acetate content < 25%. However, these compositions are unsatisfactory. The present invention proposes to obviate the drawbacks of EP-A-73613, and to provide a resin composition that has good flexibility and flame-retardancy, simultaneously. Therefore, the present invention relates to a crosslinked, flame-retardant resin composition which essentially comprises 100 weight parts of EVA-VC having 25 to 75% by weight of vinyl chloride, 10 to 70 weight parts of chlorinated polyethylene having 25 to 45% by weight of chlorine content, 40 to 120 weight parts of flame-retardant fillers, and 5 to 20 weight parts of monomer with multifunctional group, characterized by the fact that the flame-retardant fillers comprise 10 to 30 weight parts of antimony trioxide, 10 to 30 weight parts of zinc borate, and 10 to 80 weight parts of metal hydrate selected from aluminium trihydroxide and magnesium hydroxide. The flame-retardant resin composition according to the present invention comprises ethylenevinylacetate-vinylchloride graft copolymer (hereinafter "EVA-VC") as a base component, which itself has fundamental flexibility and a property of flame-retardancy, as well as a good filler-loading property. EVA is a kind of ethylenevinylacetate copolymer which is structured to have an ethylene main chain from which a number of vinylacetate groups, a volumetrically large group, are pending, and so has an excellent flexibility and a good filler-loading property. In EVA-VC, to the ethylenevinylacetate copolymer are grafted polyvinyl chloride chains having chloride groups that provide a property of flame-retardancy for the polymer. Accordingly, this polymer is suitable for the main polymer of a flame-retardant resin composition because of its inherent properties of flexibility and flame-retardancy. In addition, EVA-VC has a property in that EVA-VC is foamed by decomposed gas generated at burning. A foamed carbonated layer plays a role of a protecting wall which is capable of preventing a flammable insulator encapsulated thereby from being directly exposed to a flame, so that a sheath layer of EVA-VC is able to prevent or retard burning. Flexibility and a property of flame-retardation of EVA-VC is determined by the contents of ethylenevinylacetate and vinyl chloride. In general, the more the content of ethylenevinylacetate is high, the more flexible is EVA-VC. On the other hand, the more the content of vinyl chloride is high, the better is the property of flame-retardancy. But a quantity of vinylchlorides lower the flexibility of EVA-VC. Thus, it is important to select a proper EVA-VC in which the content ratio of ethylenevinylacetate and vinyl chloride is such that EVA-VC is excellent in a property of flame-retardancy and flexibility, simultaneously. Chlorinated polyethylene reinforces a mechanical strength and the property of flame-retardancy and improves an adhesion to polyethylene insulator. Antimony trioxide is burned with halogen such as chlorine to be formed into halogenated antimony, for example, antimony trichloride, and a group of non-volatile oxide compounds is produced in a flame to dissipate the energy of the flame. Metal hydrate contributes to an affect of flame-retardancy by a manner in that when the metal hydrate is burned in a flame, the hydrated water is vaporized to absorb the energy of the flame. Zinc borate is known to provide a synergistic effect of flame-retardancy when used in combination with antimony trioxide, and to prohibit the generation of gas when burned. Such flame-retardant fillers not only provide an improvement of the property of flame-retardancy but also support the carbonated layer of EVA-VC in order not to collapse. As the monomer with multifunctional group used in the present invention, there may be employed a monomer with bifunctional group or trifunctional group, preferably monomer with trifunctional group, such as trimethylolpropanetrimethacrylate, triarylisocyaurnate. The monomer with multifunctional group may be crosslinked by methods such as peroxide crosslinking and electron beam crosslinking. Crosslinking by electron beam energy is efficient to an extruded product such as electric wires. A three-dimensional structure is formed by crosslinking, which plays an important role in foaming and supporting the carbonated layer when burned. Therefore, the resin composition according to the present invention must be applied with a crosslinking process. In accordance with the present invention, an electric wire for high voltage-operating equipments which is structured to have a sheath layer of the present composition encapsulating an insulator for the wire has a satisfactory flexibility and property of flame-retardancy, simultaneously. The present invention will become more apparent from the following description. EXAMPLE 1 Each of the compounding components was weighed as shown in Table 1. The components were mixed in an 20.3 cm (8-inch) open roller at 140±5°C for 10 minutes, and then, two pressed sheets with thickness of 2mm and 3mm were made by press at 170°C. Specimens for testing a property of flame-retardancy and flexibility were prepared by irradiating the pressed sheets with an electron beam in exposure dose of 4 Mrad to crosslink them. The specimen sheets had 42% of oxygen index based on ASTM D2863, so that shoved an excellent property of flame-retardancy. The specimens also had -28°C by low temperature resistant hammering test based on ASTM D746, so that showed an excellent flexibility even in low temperature. A specimen for combustion test was prepared by extruding the composition with a single screw extruder of 75 mm diameter at 145°C in an extrusion velocity of 100m/min. to coat the composition on a crosslinked polyethylene insulator in a thickness of 0.9 mm, which encapsulated a copper wire of 1mm diameter in a thickness of 0.8 mm, and irradiating the resultant wire with electron beam in exposure dose of 4 Mrad. The specimen was put over a Bunsen burner in which the inner flame height and outer flame height were adjusted to be 30 mm and 127 mm, respectively. The flames from the Bunsen burner had an oblique angle of 20 to the vertical direction of wire, and put in the specimen for 15 seconds and put out for 15 seconds. The property of flame-retardancy of the specimen was tested by repeating the putting in and out five times. Flame in the specimen was extinguished instantly on putting out the flame from the Busen burner. Moreover, the specimen formed a thick and non-splitted carbonated layer when burned, which played a role of protecting or retarding the combustion of flammable insulator of crosslinked polyethylene. COMPARATIVE EXAMPLE 1 Pressed sheets and specimens for testing a property of flame-retardancy were prepared in a manner similar to Example 1 except that an extrusion temperature for the specimen for testing a property of flame-retardancy was 170°C. As a result, oxygen index as 32 which was about 10% less than that of Example 1, and was -10°C by low temperature resistant hammering test, which shoved that flexibility was inferior to that of Example 1. Furthermore, a carbonated layer formed during combustion was thinner and splitted. As a result, crosslinked flammable insulator of polyethylene flowed out so that continued to burn. EXAMPLES 2-4 Each of compounding components was weighed as shown in Table 1. Pressed sheets and specimens for testing a property of flame-retardancy were prepared in a manner similar to Example 1 to measure oxygen index and low temperature resistant hammering temperature. Their results are given as shown in Table 1. Alike, these materials were effective materials for sheath layer durable to high voltage. COMPARATIVE EXAMPLES 2-3 Pressed sheets and specimens for testing a property of flame-retardancy were prepared in a manner similar to Example 1 except that an extrusion temperature for the specimen for testing a property of flame-retardancy was 170°C. As a result, oxygen indices were about 10% less than those of Examples, and had low temperature resistant hammering temperatures of -10°C and -3°C which showed that their flexibility were inferior to those of Examples. Furthermore, carbonated layers formed during combustion were thinner and splitted. As in comparative Example 1, crosslinked flammable insulator of polyethylene flowed out so that continued to burn. Example C.Example 1 2 3 4 1 2 3 C O M P O S I T I O N EVA-VC 100 100 100 100 - - - CPE 30 20 10 50 - - - PVC(p.d=1300) - - - - 100 100 100 Tribasic lead sulfate 8 8 8 8 7 7 7 Antimony trioxide 20 15 10 30 10 10 10 Zinc borate 20 15 10 30 10 - - Magnesium hydroxide 40 60 - 20 50 - - Aluminum trihydroxide - - 80 - - - - Antioxidant 2 2 2 2 1 1 1 TOTM - - - - 50 40 30 Monomer with trifunctional group 15 10 10 20 10 5 5 Results Oxygen index (%) 42 42 41 44 32 33 35 Low temperature resistant hammering temperature (°C) -28 -30 -30 -28 -10 -10 -3 Formation of carbonated layer A A A A B C C Combustion test S S S S F F F From the results of Examples and Comparative Examples, it is apparent that the crosslinked, flame-retardant resin composition has good flexibility and a property of high flame-retardancy, simultaneously, so that the composition is suitable for the material for a sheath layer of wire or cable durable to high voltages.

Claims: A crosslinked, flame-retardant resin composition which essentially comprises 100 weight parts of EVA-VC having 25 to 75% by weight of vinyl chloride, 10 to 70 weight parts of chlorinated polyethylene having 25 to 45% by weight of chlorine content, 40 to 120 weight parts of flame-retardant fillers, and 5 to 20 weight parts of monomer with multifunctional group, characterized by the fact that the flame-retardant fillers comprise 10 to 30 weight parts of antimony trioxide, 10 to 30 weight parts of zinc borate, and 10 to 80 weight parts of metal hydrate selected from aluminium trihydroxide and magnesium hydroxide. A crosslinked, flame-retardant resin composition of claim 1, wherein the monomer with multifunctional group is a monomer with trifunctional group selected from trimethylolpropanetrimethacrylate and triarylisocyanurate. A crosslinked, insulated electric wire having a property of flame-retardancy, which is structured to have a crosslinked protecting sheath layer that encapsulates a wire coated with an insulating layer, the sheath layer essentially comprising 100 weight parts of EVA-VC having 25 to 75% by weight of vinyl chloride, 10 to 70 weight parts of chlorinated polyethelene having 25 to 45% by weight of chlorine content, 40 to 120 weight parts of flame-retardant fillers, and 5 to 20 weight parts of monomer with multifunctional group, the electric wire being characterized by the fact that the flame-retardant fillers comprise 10 to 30 weight parts of antimony trioxide, 10 to 30 weight parts of zinc borate, and 10 to 80 weight parts of metal hydrates selected from aluminium trihydroxide and magnesium hydroxide. A crosslinked, insulated electric wire having a property of flame-retardancy of claim 3, wherein the monomer with multifunctional group is a monomer with trifunctional group selected from trimethylolpropanetrimethacrylate and triarylisocyanurate.

Inventors: KIM SANG-MIN, KWON INN-KEUK, KIM, SANG MIN, KWON, IN KEUK
Applicants: GOLD STAR CABLE CO LTD, GOLDSTAR CABLE CO., LTD.
Application year: 1994
Main classification: C08L51
IPC codes: C08L27, C08K5, C08K3, C08L23, H01B7, C08F255, C08L51, C08F285, H01B3, C08K13